Toolpath dependent chatter suppression in multi-axis milling of hollow fan blades with ball-end cutter

Zhou, Xing; Zhang, Dinghua; Luo, Ming; Wu, Baohai

doi:10.1007/s00170-014-5698-6

Cited by 37 publications

(13 citation statements)

References 9 publications

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“…where ϕ j ( t ) is also the instantaneous angular immersion of tooth (j) measured clockwise from the normal (Y) axis, 9 as shown in Figure 1, Ω is the spindle speed(r/min), N is the number of milling cutter teeth, j is the j -th cutter tooth, a is the axial cutting thickness ( da is the micro element thickness in the axial direction), β is the helix angle of cutter, R is the milling cutter radius, and l is the l -th micro unit from bottom to top in the axial direction.…”

Section: Three Degrees Of Freedom Milling Chatter Modelmentioning

confidence: 99%

Chatter stability analysis of variable speed milling with helix angled cutters

Xiong

Yuan

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The number of factors considered in the establishing of chatter model for regenerative chatter would directly affect the accuracy of numerical analysis. In this paper, considering the helix angle of cutter, the establishment method of three degrees of freedom complex model is investigated synthetically. An improved semi-discretization method is adopted for the prediction of milling stability of variable speed milling with helix angle. The influences of milling cutter helix angle, radial immersion rate and variable speed modulation coefficient on chatter suppression in milling process are studied. The results show that the selection of milling cutters with different helix angles has a certain influence on the overall chatter stability, especially the effect cannot be ignored under local special machining conditions. Excessive radial immersion rate will increase the probability of chatter. Compared with constant speed milling, the chatter can be suppressed obviously by variable speed milling, and the selection of variable speed modulation coefficient will directly affect the suppression effect of chatter.

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Section: Three Degrees Of Freedom Milling Chatter Modelmentioning

confidence: 99%

Chatter stability analysis of variable speed milling with helix angled cutters

Xiong

Yuan

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…2 and isolated from other high structure modes, which adopted here is to simplify the complexity of the real system as possible. Not alike the real flexible part in industry which has multiple modes and different mode shape, such as thin-wall workpiece, blades and impellers, the different mode shapes of part structure make the frequency response function varying with cutting path [5,6,[18][19][20][21]. However, the method presented here can be easily extended to consider the multiple-mode cases.…”

Section: Model Parameter Identification and Model Simplificationmentioning

confidence: 99%

A synthetical stability method for cutting parameter optimization to assure surface location accuracy in flexible part milling

Zhang

Chen

Ding

et al. 2014

Int J Adv Manuf Technol

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Flexible parts are widely used in the aeronautic and power industries which have high machining accuracy requirement. However, the flexible part is apt to vibrate in cutting processes due to its low structure stiffness and damping. Accurate approximation of cutting stability boundary of flexible part is difficult, because traditional stability analysis simplifies the complex dynamic system and some parameters still have large vibrations and can cause bad surface accuracy even when they are predicted to be located in the stable zone. To better evaluate the stability in flexible part milling, a synthetical stability method is proposed to calculate the boundary which can assure both the cutting stability and the surface location accuracy. To exclude other factors which may have great effect on cutting stability, such as multiple structure modes and structure mode coupling, etc, a flexible support platform is designed to test the validity of the classical local stability analysis. After the comparison between the local stability prediction and the experimental results, it is found that the local stability analysis is defective for the stability prediction of the flexible part milling. Therefore, the dynamical equation is improved and both the periodical excitation and the regenerative excitation are considered. The stability boundary is calculated by using the time-domain numerical method, with the radial immersion and cutting entrance angle's variation originated from forced vibration being considered. The simulation based on the synthetical stability analysis has a good agreement with the experimental results, which verifies the validity of the presented method.

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“…Therefore, using appropriate high-speed machining parameters, it is necessary to achieve high productivity while also maintaining the required machining accuracy and quality. On the other hand, due to the low stiffness of thin-walls, it is also recommended to avoid the appearance of vibrations and deformations, which can cause machining errors, low quality, and the appearance of scrap [6][7][8][9]. The main causes for the appearance of these errors in the literature are the type of material, elements of machining system (machine, tool, fixtures), cutting parameters, machining strategies, metalworking fluids and coolants, wall thickness, and others [2,5,[10][11][12][13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Multi-Criteria Selection of the Optimal Parameters for High-Speed Machining of Aluminum Alloy Al7075 Thin-Walled Parts

Lukić

Čep

Vukman

et al. 2020

Metals

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Thin-walled parts made of aluminum alloy are mostly used as structural elements in the aerospace, automobile, and military industries due to good homogeneity, corrosion resistance, and the excellent ratio between mechanical properties and mass. Manufacturing of these parts is mainly performed by removing a large volume of material, so it is necessary to choose quality machining parameters that will achieve high productivity and satisfactory quality and accuracy of machining. Using the Taguchi methodology, an experimental plan is created and realized. Based on its results and comparative analysis of multi-criteria decision making (MCDM) methods, optimal levels of machining parameters in high-speed milling of thin-walled parts made of aluminum alloy Al7075 are selected. The varying input parameters are wall thickness, cutting parameters, and tool path strategies. The output parameters are productivity, surface quality, dimensional accuracy, the accuracy of forms and surface position, representing the optimization criteria. Selection of the optimal machining parameter levels and their ranking is realized using 14 MCDM methods. Afterward, the obtained results are compared using correlation analysis. At the output, integrative decisions were made on selecting the optimal level and rank of alternative levels of machining parameters.

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Toolpath dependent chatter suppression in multi-axis milling of hollow fan blades with ball-end cutter

Cited by 37 publications

References 9 publications

Chatter stability analysis of variable speed milling with helix angled cutters

Chatter stability analysis of variable speed milling with helix angled cutters

A synthetical stability method for cutting parameter optimization to assure surface location accuracy in flexible part milling

Multi-Criteria Selection of the Optimal Parameters for High-Speed Machining of Aluminum Alloy Al7075 Thin-Walled Parts

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